520 Electrical

8/13/2019 520 Electrical

1/24

/ j , R. HFog light

A L. H ~"'1i1 "~~~~,,

Fog light()=J

1.H Parking &

directional light

Stop

light

Light relay switch

Horn relay

H

Engine room c n :::::: :; - Ii'L

light ~

Hood switch-RB

li'w

g~c'(RG

YW

~ ~;:ssure switch

Thermal)! Vo~tage regulator

transmi tter

w~

B/6 .

81 DIrectionalGB light

GR switch FrameRG ~ earthGW~N)

~~Lighting switch

y lJ.~Wo~Dki r E l . DoorLW~I WIper switch~~(t switchflY

7Q~ Room ~M'jj::::::::tL..J Heater lam p

switchL':>

~=-:l[JIgnition switch

L/R----....r-lCigarette A~ lighter

B

WCombination

meter R

G

Y

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1.1.;

D.L.I.;

M.B.;

G.1. ;

O. P.L.;

Instrument light

Directional Light Indicator

Main Beam Indicator

Genera tor Indica tor

Oil Pressure Warning Light

3.~The size of electric line is 0.5 mm except

(marked the size. .

4. The parts marked L ::. means optional

equipment.

R~ b' .f om matIonw

80 light

GW4Licence light

~t t i : ~" O

IllbRncombination

~ light

LINE COLOURS

, ... , BLA CK

. , .. :... WHITE

........ RED

..... GREEN

.... YELLOW

... , . BLUE


2/24

Head lamp(R.H)

Parking {; turnsignal lamp

(R.H)

Fog lamp(R.H)

(option)

Fog lamp(L.H)

(option)

Parking {;turnsignal lamp

(L.H)

Head lamp

(i.H)

Engine room lamp RL

Hood sWitch~. r~

Light relay Stop l~mpA Reverse lamp'--~-l sWItchrr switchiS7435 W Horn relay W =1 I! J l " " 30 : H BS :>- L

Qr : : Co : : ~


3/24

Alternator

Nominal output 12 volt - 300W

Constant revolution 2500 rpm.

RPM to get 14 bolt,

Under 1000 rpm.

No load (normal temp.) rpm. 2500

voltage 14.50.5V

Polarity2500 rpm. I eearthrpm.

voltage 14V

Out put current 21.5A

I 24.5A

current more than more than

Put-off voltage

4.5-5.2V

Put- on voltage

0.5 -3V

Different from the DC generator, the AC

generator turns the magnetic pole and fixes the

armature making it generates 3-phase alternate

current, and rectifies all waves with the silicon

diode, (+), (-) each three, that are built within,

and takes out as direct current.


4/24


5/24

Regulatorr-----------

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When the ignition switch is put on, the bat-

tery current flows in the arrow marked direction

passing through the dynamo E terminal, brush

slip ring, field coil, slip ring, rbush, dynamo

F terminal, relay F terminal and IG terminal

and completes the filed circuit. It in difficult

for the dynamo to stand up only by residual

magnetism of the field core, so that magnetiza-

tion is necessary until voltage rises to suit

charging after the engine has started.

This is because the diode is used and when

the voltage to add to it is so low, large propor-

tional resistance shows up and current does not

flow through the field coil unless the dynamo

makes very high revolution.

Disassembly and Assembly

A. Disassembly

The dynamo is disassembled in the fol-

lowing order.

ELECTRICAL SYSTEM

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Remove the brush cover and pull of the

brush, 2 ea.

Remove the cove-r of bearing and take

off the hex. bolt of shaft.

Remove the hex. nut of pulley and pull

off the pulley and the half-moon key.

Be careful not to injure the fan when the

nut is removed.


6/24


7/24

To remove a diode, use a suitable tool to

support the end of the frame, or heat sink,

and push the diode out by using. an arbor

press as shown the below.

Press out so asnot t

injure the mounting

bore of the frame or

the heat sink.

Installation

Support the heat sink or end frame with a

suitable tool and then press the diode in theheat sink and end frame by using the tool

shaped which fits over the outer diode edge

A portion.

Press down perfectly the diode in the

mounting bore of C portiOn' to the lower edge

of B portion of the diode.

Checking the replaced diodes.

Inspection of Troubles

A. Inspection of Output

For inspection of output, remove thedynamo from the vehicle and connect wiring

as shown in Fig. 3. 1 and drive it with motor.

(For inspection of output of dynamo without

removing it from the vehicle, refer to "In-

spection of AC generator" to be published

later. )

Fig. 2-3. 1

Note: Use the battery charged in full up to

the normal capacity.

Through the wiring shown in Fig. 3. 1,

magnetic current flows from the battery to

the filed coil of dynamo. In this state, raise

revolution of dynamo slowly up to the speed

where there is no reverse flow (2 A approx.)

to the field coil and read the revolution.

Correct revolution is approx.

1000 rpm. without load.

Next, increase load resistance to the

maximum and almost stop flowing of load

current, and put off the switch. Then, rais-

ing the load current slowly, increase re-

volution of dynamo. Observe thus increasing

output current as revolution of dynamo in-

creases. If there is no large difference

from the specification, it is correct.

No matter how the battery is over-

charged or discharged, if the charging cur-

rent is small, first make sure either the

dynamo or the relay is in disorder. See thecharging current by inserting the ammeter

between A terminal of relay and the battery.

Disconnect wire passing from the dynamo

F terminal to the relay F terminal at the

relay F terminal and make the removed lead

wire short circuits at the relay A terminal,

when if the charging current highly increases,

the relay is in disorder.


8/24

B. Short Circuits on Diode "-" Side

It can be judged as the pilot lamp does not

flare even if the key switch is turned on.

Actually a trouble such as "diode open" is

very rare and short circuits at the polar line

are also rare. . Ordinarily, there are many

cases of"+" side short circuits.

C. Inspection of Diode with Tester

a) Simple Inspection

Check between the terminals, A - N as

shown in Fig. 3. 2.

Set the dial of tester for conductivity and

put the tester needles at both terminals

alternately.

When one shows low resistance and the

other shows pretty high resistance, the

3 diodes in the diode set are all right.

Check between the terminals, A - E

same as above.

When the same result is obtained, 3

diodes are also all right.

However, when there is no disorder

found in this simple test and the dynamo

output is somewhat lower than the

standard, 1-2 diodes are often in open-

ing, when one by one checking will benecessary.

Check resistance with the tester between

the diode base commonly used for 2 diodes

and lead wire on the rear cover - 2 times

changing the poles, When one side shows

low resistance and the other shows high

resistance, there is no disorder. If both

sides are low, there will be short circuit and

both sides are high there will be open.


9/24

D. Inspection of Diode with Lamp

a) Simple Inspection

Test Method

Test Lamp Method

Test Method

Test Lamp Method

Connection Lamp Result Connection Lamp Result

Should be con- Connect EBtoLight Good Should be

Connect8toLight Good

ductive to and8tonon- conduc-

andEBtoNo light Defective tive to No light Defective

Should be non-Connect8to

No light Good Should beConnect8to

Light Defective

conductive @andEBto

conductiveandEBto

to Light Defective to IF) No light Good

The soldering for the lead wires should

be performed in less than 20 seconds, as the

excessive heat may damage the diodes.

put both ends at A and N terminals alternate-

ly. On one side the lamp flares and on the

other the lamp is off, when 3 diodes of the

diode set are all right.

Check between the terminals, A - N as

shown in Fig. 3. 6.

Connect with the lamp (12V) in straight and

The same step is taken between the ter-

minals, N - E. When the same result is

obtained, 3 diodes pressed in the cover are


10/24

DATSUN PICK-UP

all right. However, if the simple test is all

right, but when the dynamo output is lowerthan the standard, 1....,..2 diodes may often be

opening, so that one by one check will be

necessary.

Checkbetween the lead wire andthe diode

set common with the other 2 diodes or the

rear cover with the lamp and battery. It is

all right if one side flares and the other is

off. If both sides flare, there is short circuit

and both sides are off, there is open.

As shown in Fig. 3. 10, put the tester

between the slip ring of rotor and if thereare 6 ....7n, it is all right. Make sure there

is no conduction between the rotor slip ringand the shaft.

Both sides sealed ball bearing is used, so

lubrication is not necessary.

\

\

If the terminal connected to the diode is

not conductivewith the stator core, that is all

right.


11/24

If each terminal ofthe coil and the ter-

minal connected to N terminal are not con-

ductive, that is all right.

Connect the tester cord to 100Vwire,

put the stator on the test stand and make the

tester one turn reading the ammeter. If

there is short circuit onthe coil, swings of

the ammeter abruptly increase and if there

is no trouble, there will be no changed.

Wipe with clean cloth when oil or dust is

onthe contact surface of brush and slip ring.

Same as in case of DCgenerator, replace

the brush when wear of it reached to the

wear limig.

ELECTRICAL 5 YST EM

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Fig. 3-1. 2

Whenthe ignition switch is on, current from

the battery passes through the dynamo E termi-

nal, field coil, contact points P2' P1 and the

dynamois magnetized.

While it also flows the regulator E terminal,

contact points P5, P4 and the lamp flares.

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12/24

When the engine starts and the dynamo is

driven, three phase alternate current generates,on the stator coil, passing through the three

phase all wave rectifier (diode) and changes to

direct current between the terminal A - E for

charging.

At the N terminal, voltage, half of that be-

tween A - E, generates and passes through thecircuit, N terminal, VCI, coil E terminal and

with action of the VC coil, the movable contact

point Ps leaves from P4 and makes contact with

P6, so that the lamp is off and it passes through

the circuit, E terminal, contact points Ps, P6,

resistance R2' VC2 coil and A terminal, then the

VC2 coil animated and prepares to vibrate the

movable contact point P2 of the constant voltage

relay.

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Fig. 3-1. 4When the dynamo revolution gets higher, the

contact point P2 separates from PI with electric

magnetism of the VC2 coil and the field current

from the circuit of the dynamo E terminal, field

coil, F terminal and resistance RI and when thecontact point P2 contacts with PI, the current

flows through the circuit of dynamo E terminal,

field coil, F terminal, contact points P2, Pl.

This is repeated according to vibration of the

contact point P2 and the dynamo terminal voltage

is kept evenly and continues charging.

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520 Electrical